Battery-powered cordless cleaning system

ABSTRACT

A cleaning system including a motor, an impeller driven by the motor, a battery receptacle, and a motor controller. The battery receptacle is configured to receive a battery pack. The battery pack includes one or more battery cells and a battery controller. The motor controller is configured to receive from the battery controller one of a first type of data and a second type of data, and operate the motor at a defined speed, the defined speed being a first speed upon receiving the first type of data, and a second speed upon receiving the second type of data.

RELATED APPLICATION

The present application claims priority to U.S. Provisional Application61/907,725, filed Nov. 22, 2013, the entire contents of which areincorporated herein by reference.

BACKGROUND

The invention relates to consumer devices, such as vacuum cleaners.

SUMMARY

Cleaning systems include a wide range of products designed to meet awide variety of cleaning needs. Examples of cleaning systems includestick-type vacuums, lightweight upright vacuums, hand-held vacuums,carpet cleaners, canister vacuums, etc.

In one embodiment, the invention provides a cleaning system including amotor, an impeller driven by the motor, a battery receptacle, and amotor controller. The battery receptacle is configured to receive abattery pack. The battery pack includes one or more battery cells and abattery controller. The motor controller is configured to receive fromthe battery controller one of a first type of data and a second type ofdata, and operate the motor at a defined speed, the defined speed beinga first speed upon receiving the first type of data, and a second speedupon receiving the second type of data.

In another embodiment the invention provides a method of operating acleaning system. The method including receiving a first battery packincluding a first battery controller; receiving a first type of datafrom the first battery controller; outputting a first control signalbased on the first type of data; operating a motor at a first speedbased on the first control signal; receiving a second battery packincluding a second battery controller; receiving a second type of datafrom the second battery controller; outputting a second control signalbased on the second type of data; and operating the motor at a secondspeed based on the second control signal.

Other aspects of the invention will become apparent by consideration ofthe detailed description and accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of a cleaning system.

FIG. 2 is a block diagram illustrating the electrical and electroniccomponents of the cleaning system of FIG. 1.

FIG. 3 is a flow chart illustrating an operation of the cleaning systemof FIG. 1.

FIG. 4 is a flowchart illustrating an operation of the cleaning systemof FIG. 1.

DETAILED DESCRIPTION

Before any embodiments of the invention are explained in detail, it isto be understood that the invention is not limited in its application tothe details of construction and the arrangement of components set forthin the following description or illustrated in the following drawings.The invention is capable of other embodiments and of being practiced orof being carried out in various ways.

A cleaning system includes a motor, a battery receptacle, and acontroller, such as a motor controller. The cleaning system receives afirst battery pack or a second battery pack. The controller electricallyand/or communicatively couples to the first battery pack or the secondbattery pack. The controller receives data from the first battery packor the second battery pack and operates the motor based on the receiveddata. In one example, the controller receives a first set of data fromthe first battery pack and a second set of data from the second batterypack. The controller operates the motor at a first speed if the firstset of data is received and at a second speed if the second set of datais received.

FIG. 1 illustrates a cleaning system 100. Although illustrated as astick-type vacuum, the cleaning system 100 can be other types ofcleaning systems (e.g., lightweight upright vacuums, hand-held vacuums,carpet cleaners, canister vacuums, bag vacuums, upright vacuums, etc.)The cleaning system 100 includes a handle portion 105 and a body portion110. In some constructions, the handle portion 105 and the body portion110 are connected via a spine 115.

The handle portion 105 includes a first section 120 and a second section125. The first section 120 may be oblique with respect to the secondsection 125 and includes a grip portion 130. The grip portion 130 isused by a user to grip and control the cleaning system 100.

In some constructions, such as the one illustrated, one or moreuser-controlled switches 135 are located near the spine 115 on the bodyportion 110. However, in other constructions, the one or moreuser-controlled switches 135 may be located on the grip portion 130. Inyet other constructions, the one or more user-controlled switches 135are located on the spine 115 or in other areas of the body portion 110.The one or more user-controlled switches 135 provide operational controlof the cleaning system 100 to the user. In some constructions, the oneor more user-controlled switches 135 are two-position switches, havingfor example, an on-position and an off-position.

In some constructions, the second section 125 includes one or moreindicators for providing indications to a user related to theoperational mode of the cleaning system 100. In some constructions, theone or more indicators are light-emitting diodes (LEDs).

The handle portion 105 may be removably coupled to the body portion 110.For example, the handle portion 105 may be detachable from the bodyportion 110 providing a suction force or vacuum through at least aportion of the handle portion 105 as a wand, or may be removable forstorage or transport purposes. In some constructions, the handle portion105 is coupled and secured to the body portion 110 via friction only. Inother constructions, the handle portion 105 is coupled and secured tothe body portion 110 via a screw or other suitable fashionable device.The handle portion 105 further includes a plurality of electricalconnectors located at an interface between the handle portion 105 andthe body portion 110. The electrical connectors electrically connect thehandle portion 105 to the body portion 110, so that electrical signalsrelated to the operation of the cleaning system 100 can be sent from thehandle portion 105 to the body portion 110 to control, for example, amotor/fan assembly and/or a brush-roll assembly.

The body portion 110 includes a battery receptacle 140, a motor/fanassembly 145, and a refuse chamber 150. In some constructions, the bodyportion 110 can further include a cyclonic separator. Alternatively, thebody portion 110 can further include a disposable bag for dirtcollection. The battery receptacle 140 receives a battery pack 155. Thebattery receptacle 140 includes a plurality of electrical connectors forelectrically connecting the battery pack 155 to the cleaning system 100.

The motor/fan assembly 145 includes a suction motor 160 (FIG. 2) and arotor, such as an impeller or a fan, coupled to the suction motor 160.In some constructions, the suction motor 160 is a brushlessdirect-current (BLDC) motor operable at multiple speeds, for example, ahigh-speed and a low-speed. In other constructions, the suction motor160 can be a variety of other types of motors, including but not limitedto, a single speed motor, a variable speed motor, a brush DC motor, astepper motor, a synchronous motor, or other DC or AC motors.

The refuse chamber 150 is positioned below the motor/fan assembly 145,and is removably coupled to the cleaning system 100 (e.g., removablycoupled to the spine 115, the body portion 110, the motor/fan assembly145, etc.). In some constructions, the refuse chamber 150 and themotor/fan assembly 145 are removably coupled together, and form a singleunit when coupled together. In such a construction, the single unit isthen removably coupled to the spine 115 and/or body portion 110. In theillustrated construction, the refuse chamber 150 is bagless and includesa latching mechanism which secures the refuse chamber 150 to thecleaning system 100. The refuse chamber 150 further includes an inletfor receiving refuse. In other constructions, the refuse chamber 150includes the disposable bag for collecting refuse.

A lower end of the body portion 110 includes an interface attaching thebody portion 110 to a base portion 165. The base portion 165 includes acorresponding interface for attaching to the body portion 110. Thehandle portion 105 and the body portion 110 pivotally move about a firstaxis parallel to a cleaning surface (e.g., the ground). Pivotal movementabout the first axis allows the handle portion 105 and the body portion110 to be moved from a position approximately perpendicular to the baseportion 165 to a position approximately parallel to the ground. Forexample, the handle portion 105 and body portion 110 are able to bemoved through an angle of between approximately 0.0° and approximately90.0° with respect to the base portion 165. In other constructions, thehandle portion 105 and body portion 110 are pivotable through larger orsmaller angles.

The handle portion 105 and body portion 110 are also pivotable along asecond axis. The second axis is approximately perpendicular to the firstaxis and is approximately parallel to the handle portion 105 and bodyportion 110. Pivotal movement about the second axis provides additionalcontrol and maneuverability of the cleaning system 100. In someconstructions, a pivot joint is employed to allow movement about thefirst axis and the second axis. In other constructions, a ball joint isemployed rather than the pivot joint.

The base portion 165 includes a first wheel 170, a second wheel 175, asuction inlet 180, and a brush-roll assembly 185. The first and secondwheels 170, 175 are rotatably coupled to the base portion 165. Thesuction inlet 180 allows refuse to enter into the cleaning system 100.In some constructions, the suction inlet 180 further includes anaperture which allows larger objects to enter the suction inlet 180without requiring the user to lift the cleaning system 100.

The brush-roll assembly 185 includes a brush and a brush-roll motor 190(FIG. 2). In some constructions, the brush-roll motor 190 is a BLDCmotor operable at multiple speeds, for example, a high-speed and alow-speed. In other constructions, the brush-roll motor 190 can be avariety of other types of motors, including but not limited to, a singlespeed motor, a variable speed motor, a brush DC motor, a stepper motor,a synchronous motor, or other DC or AC motors.

FIG. 2 is a diagram illustrating electrical and electronic components ofthe cleaning system 100. In the illustrated construction, the electricaland electronic components of the cleaning system 100 are containedwithin the battery pack 155, a main body housing 200, a motor/fanassembly housing 205, and a brush-roll assembly housing 210. In otherconstructions, the electrical and electronic components of the cleaningsystem 100 may be contained within more, less, or different housings.

The battery pack 155 includes one or more battery cells 215. In someconstructions, the battery cells 215 are rechargeable lithium-ionbattery cells. In other constructions, the one or more battery cells 215may have a chemistry other than lithium-ion, such as but not limited to,nickel cadmium, nickel metal-hydride, etc. Additionally oralternatively, the one or more battery cells 215 may be non-rechargeablebattery cells. The one or more battery cells 215 may be electricallyconnected in a series-type connection, a parallel-type connection, orboth a series and parallel type connection.

The battery pack 155 further includes a battery controller 220. Thebattery controller 220 includes a processing unit (e.g., amicroprocessor, a microcontroller, or another suitable programmabledevice) and a memory unit. In some constructions, the battery controller220 is implemented partially or entirely on a semiconductor (e.g., afield-programmable gate array [“FPGA”] semiconductor) chip. In someconstructions, the battery controller 220 senses/monitors a variety ofcharacteristics of the battery cells 215, including but not limited to,voltage, current, capacity, resistance, temperature and number of cells.In some constructions, if any of the sensed/monitored characteristics ofthe battery cells 215 are out of a predetermined range, the batterycontroller 220 prohibits the battery pack 155 from outputting current.

The battery pack 155 selectively couples to main body housing 200 viathe battery receptacle 140. The battery pack 155 selectively couples tothe battery receptacle 140 through the use of one or more latchingmechanisms. The battery pack 155 electrically connects to the main bodyhousing 200 through a plurality of terminals. In the illustratedconstruction, the plurality of terminals include positive batteryterminals 225 a, 225 b, negative battery terminals 230 a, 230 b, anddata serial line, or communications, terminals 235 a, 235 b. Thecleaning system receives power through the positive battery terminals225 a, 225 b and is electrically grounded through the negative batteryterminals 230 a, 230 b. The battery pack 155 outputs and/or receivesdata, or serial data, through the communications terminals 235 a, 235 b.

The battery receptacle 140 is configured to receive either a firstbattery pack or a second battery pack. Further, the cleaning system 100is configured to be powered by either the first battery pack or thesecond battery pack. In some constructions, the first battery pack hasdifferent characteristics than the second battery pack. For example, butnot limited to, the first battery pack may have a first capacity (e.g.,2 A-h), while the second battery pack may have a second capacity (e.g.,4 A-h). The characteristics may further be any of, or any combinationof, voltage, current, resistance, number of cells, batteryidentification code, etc. When releasably coupled to the batteryreceptacle 140, the first battery pack outputs a first type of datathrough the communications terminals 235 a, 235 b. The first type ofdata is identification data identifying the first battery pack, or dataindicative of one or more characteristics of the first battery pack.Additionally, when releasably coupled to the battery receptacle 140, thesecond battery pack outputs a second type of data through thecommunications terminals 235 a, 235 b. The second type of data isidentification data identifying the second battery pack, or dataindicative of one or more characteristics of the second battery pack.The battery pack 155 as discussed herein can be either the first batterypack or the second battery pack.

The main body housing 200 of the cleaning system 100 includes a switchboard 240. The switch board 240 selectively controls power from thebattery pack 155 to a variety of electrical components of the cleaningsystem 100, such as but not limited to electrical components of themotor/fan assembly housing 205 and the brush-roll assembly housing 210.In some constructions, the switch board 240 is operated by the one ormore user-controlled switches 135. In the illustrated construction, theone or more user-controlled switches 135 include a main power switch 245and a brush-roll switch 250. In such a construction the main powerswitch 245 provides power from the battery pack 155 to electricalcomponents within the motor/fan assembly housing 205 and the brush-rollassembly housing 210, while the brush-roll switch 250 provides powerfrom the battery pack 155 to electrical components within the brush-rollassembly housing 210. In some constructions, the switch board 240 mayinclude more or less components. For example, the switch board 240 mayinclude one or more fuses, one or more positive temperature coefficient(PTO) devices, etc.

In some constructions, such as the one illustrated, the main bodyhousing 200 further includes a light 255. In such a construction, themain power switch 245 selectively provides power from the battery pack155 to the light 255. Upon receiving power, the light 255 illuminates.In some constructions, the light 255 is located on the base portion 165.The light 255 can be one of a light-emitting diode (LED) or anincandescent light bulb.

The main body housing 200 electrically connects to the motor/fanassembly housing 205 via a plurality of electrical terminals, includingmotor/fan power terminals 260 a, 260 b, motor/fan ground terminals 265a, 265 b, and motor/fan communication terminals 270 a, 270 b.

The motor/fan assembly housing 205 includes a speed control module 275connected to the suction motor 160. The speed control module 275operates the suction motor 160 at a defined speed. In someconstructions, the speed control module 275 is a controller that outputsa control signal to the suction motor 160. The control signal operatesthe suction motor 160 at the defined speed. In one construction, thespeed control module 275 outputs a first control signal to operate thesuction motor 160 at a first speed, and outputs a second control signalto operates the suction motor 160 at a second speed. In someconstructions, the control signal is a pulse-width modulated (PWM)signal having a voltage and a duty cycle (e.g., 10%, 25%, 50%, 75%,etc.). The average voltage value of the PWM signal is output to thesuction motor 160 in order to operate the suction motor 160. A PWMsignal having a high average voltage drives the motor at a high motorspeed. A PWM signal having a low average voltage drives the motor at alow motor speed.

The speed control module 275 receives power through the motor/fan powerterminals 260 a, 260 b and is grounded through motor/fan groundterminals 265 a, 265 b. The speed control module 275 further receivesdata through the motor/fan communication terminals 270 a, 270 b. In theillustrated construction, the data received through the motor/fancommunication terminals 270 a, 270 b is from the battery controller 220of the battery pack 155. In some constructions, the speed control module275 receives data from the battery controller 220, determines a motoroperating speed based on the received data, and outputs a control signalindicative of the motor operating speed to the suction motor 160. Forexample, the data may be a first type of data from the first batterypack or a second type of data from the second battery pack. The speedcontrol module 275 interprets the received data and operates the suctionmotor 160 at a first speed when the first type of data is received(i.e., the first battery pack is connected) or at a second speed whenthe second type of data is received (i.e., the second battery pack isconnected).

In other constructions, the speed control module 275 receives a motoroperating speed from the battery controller 220, and outputs a controlsignal indicative of the motor operating speed to the suction motor 160.For example, the speed control module 275 may receive a first type ofdata related to a first operating speed or a second type of data relatedto a second operating speed. The speed control module 275 operates thesuction motor 160 at the first operating speed (i.e., when the firstbattery pack is connected) or at the second operating speed (i.e., whenthe second battery pack is connected).

In some constructions, the motor/fan assembly housing 205 selectivelycouples to the main body housing 200 via one or more latchingmechanisms. In other constructions, the motor/fan assembly housing 205is permanently affixed to the main body housing 200.

The main body housing 200 electrically connects to the brush-rollassembly housing 210 via a plurality of electrical terminals. In theillustrated construction, the plurality of terminals includes brush-rollpower terminals 280 a, 280 b and brush-roll ground terminals 285 a, 285b. In other constructions, there may further be brush-roll communicationterminals.

The brush-roll assembly housing 210 includes a switch 290 and thebrush-roll motor 190. The switch 290 receives power through thebrush-roll power terminals 280 a, 280 b and selectively provides powerto the brush-roll motor 190. Upon receiving power, the brush-roll motor190 rotates the brush. The brush-roll motor 190 is ground through thebrush-roll ground terminals 285 a, 285 b.

In some constructions, the switch 290 is activated when the cleaningsystem 100 is in an operation position, such as when the handle portion105 and the body portion 110 are tilted downward along the first axis atan approximate angle of less than 90°. In such a construction, theswitch 290 is deactivated when the cleaning system 100 is in an uprightposition, such as when the handle portion 105 and the body portion 110are tilted upward along the first axis at an angle equal toapproximately 90°.

In some constructions, the brush-roll motor 190 is operated by the speedcontrol module 275, or the control signal from the speed control module275. In such a construction, the brush-roll motor 190 receives thecontrol signal from the speed control module 275 through the brush-rollpower terminals 280 a, 280 b. The brush-roll motor 190 operates at aspeed (e.g., a first brush-roll-motor speed, a second brush-roll-motorspeed, etc.) based on the control signal.

FIG. 3 is a flow chart illustrating an operation 300 of the cleaningsystem 100. Although illustrated as occurring in a sequential order, itshould be understood that the order of the steps discloses in operation300 may vary. Furthermore, additional steps may be included in theoperation 300 and not all of the steps may be required. The batteryreceptacle receives the battery pack 155 (Step 305). The cleaning system100 is powered on (Step 310). The speed control module 275 received datafrom the battery pack 155 (Step 315). The speed control module 275operates the suction motor 160 at a defined speed based on the receiveddata (Step 320).

FIG. 4 is a flow chart illustrating a specific operation 400 of thecleaning system 100. Although illustrated as occurring in a sequentialorder, it should be understood that the order of the steps discloses inoperation 400 may vary. Furthermore, additional steps may be included inthe operation 400 and not all of the steps may be required. The batteryreceptacle 140 receives the first battery pack or the second batterypack (Step 405). The cleaning system 100 is powered on (Step 410). Thespeed control module 275 receives data from the battery pack 155 (Step415). The speed control module 275 determines if the data is a firsttype of data (Step 420). If the received data is a first type of data,the speed control module 275 operates the suction motor 160 at a firstspeed (Step 425). If the received data is not a first type of data, andthus a second type of data, the speed control module 275 operates thesuction motor 160 at a second speed (Step 430).

Thus, the invention provides, among other things, a cleaning systemconfigured to receive a battery pack and operate a suction motor basedon the data received from the battery pack. Various features andadvantages of the invention are set forth in the following claims.

What is claimed is:
 1. A cleaning system comprising: a motor; animpeller driven by the motor; a battery receptacle configured to receivea battery pack, the battery pack including one or more battery cells anda battery controller; and a motor controller configured to receive fromthe battery controller one of a first type of data and a second type ofdata, and operate the motor at a defined speed, the defined speed beinga first speed upon receiving the first type of data, and a second speedupon receiving the second type of data.
 2. The cleaning system of claim1, wherein the battery receptacle is configured to receive one of thebattery pack and a second battery pack.
 3. The cleaning system of claim2, wherein the motor controller receives the first type of data from thebattery controller of the battery pack and the second type of data froma second battery controller of the second battery pack.
 4. The cleaningsystem of claim 3, wherein the first type of data is a first batterycapacity and the second type of data is a second battery capacity. 5.The cleaning system of claim 1, wherein the first type of data is acharacteristic of the battery pack.
 6. The cleaning system of claim 1,wherein the first type of data is a battery identification code.
 7. Thecleaning system of claim 1, further comprising a second-motor.
 8. Thecleaning system of claim 7, wherein the second-motor is operated at asecond defined speed according to the data.
 9. The cleaning system ofclaim 8, wherein the second defined speed is a first second-motor speedwhen the motor controller receives the first type of data, and a secondsecond-motor speed when the motor controller receives the second type ofdata.
 10. The cleaning system of claim 7, wherein the second-motordrives a brush-roll.
 11. A method of operating a cleaning system, themethod comprising: receiving a first battery pack including a firstbattery controller; receiving a first type of data from the firstbattery controller; outputting a first control signal based on the firsttype of data; operating a motor at a first speed based on the firstcontrol signal; receiving a second battery pack including a secondbattery controller; receiving a second type of data from the secondbattery controller; outputting a second control signal based on thesecond type of data; and operating the motor at a second speed based onthe second control signal.
 12. The method of claim 11, wherein the firsttype of data is a first battery capacity and the second type of data isa second battery capacity.
 13. The method of claim 11, furthercomprising operating a second-motor at the first speed based on thefirst control signal; and operating the second-motor at the second speedbased on the second control signal.
 14. The method of claim 11, whereinthe motor drives one selected from the group of an impeller and abrush-roll.
 15. The method of claim 11, wherein the first type of datais a first characteristic of the first battery pack and the second typeof data is a second characteristic of the second battery pack.
 16. Acleaning system comprising: a motor; an impeller driven by the motor; abattery receptacle configured to receive a first battery pack and asecond battery pack; and a controller configured to receive a first typeof data from the first battery pack and a second type of data from thesecond battery pack, operate the motor at a defined speed, the definedspeed being a first speed based on the first type of data, and a secondspeed based on the second type of data.
 17. The cleaning system of claim16, wherein the first type of data is a first battery capacity and thesecond type of data is a second battery capacity.
 18. The cleaningsystem of claim 16, further comprising a second-motor.
 19. The cleaningsystem of claim 18, wherein the second-motor is operated at a seconddefined speed, the second defined speed is a first speed when the motorcontroller receives the first type of data, and a second speed when themotor controller receives the second type of data.
 20. The cleaningsystem of claim 18, wherein the second-motor drives a brush-roll.